A method of securing an insert in a preselected region of a workpiece. An opening wall is formed in the workpiece with an opening wall surface defining an opening to produce a remainder segment of the workpiece. The opening encompasses or coincides with the preselected region. An insert is provided to fit in the opening. An insert heated portion and a remainder segment heated portion are heated to a hot working temperature, at which they are plastically deformable. While the insert is subjected to an engagement motion, to move the insert relative to the remainder segment, an insert engagement surface of the insert is pressed against the opening wall surface, for plastic deformation of the insert heated portion and of the remainder segment heated portion, creating a metallic bond between the insert and the remainder segment. The insert and the remainder segment are allowed to cool, to bond them together.

In some implementations, an injection system that injects sealant into a pipe, pressure component or valve while containing the pipe, pressure component or valve repair that significantly reduces or eliminates release of hazardous material from inside the pipe, pressure component valve or injection system and thus significantly reduces emission of the hazardous material from inside the pipe, pressure component or valve into the environment and protecting the repair technicians.

An aluminum alloy material contains Si: 1.0 mass % to 5.0 mass % and Fe: 0.01 mass % to 2.0 mass % with balance being Al and inevitable impurities, wherein 250 pcs/mm.sup.2 or more to 710.sup.5 pcs/mm.sup.2 or less of Si-based intermetallic compound particles having equivalent circle diameters of 0.5 to 5 m are present in a cross-section of the aluminum alloy material, while 100 pcs/mm.sup.2 to 710.sup.5 pcs/mm.sup.2 of Al-based intermetallic compound particles having equivalent circle diameters of 0.5 to 5 m are present in a cross-section of the aluminum alloy material. An aluminum alloy structure is manufactured by bonding two or more members in vacuum or a non-oxidizing atmosphere at temperature at which a ratio of a mass of a liquid phase generated in the aluminum alloy material to a total mass of the aluminum alloy material is 5% or more and 35% or less.

An aluminum alloy material contains Si: 1.0 mass % to 5.0 mass % and Fe: 0.01 mass % to 2.0 mass % with balance being Al and inevitable impurities, wherein 250 pcs/mm.sup.2 or more to 710.sup.5 pcs/mm.sup.2 or less of Si-based intermetallic compound particles having equivalent circle diameters of 0.5 to 5 m are present in a cross-section of the aluminum alloy material, while 100 pcs/mm.sup.2 to 710.sup.5 pcs/mm.sup.2 of Al-based intermetallic compound particles having equivalent circle diameters of 0.5 to 5 m are present in a cross-section of the aluminum alloy material. An aluminum alloy structure is manufactured by bonding two or more members in vacuum or a non-oxidizing atmosphere at temperature at which a ratio of a mass of a liquid phase generated in the aluminum alloy material to a total mass of the aluminum alloy material is 5% or more and 35% or less.

Hybrid bonded turbine rotors and methods for manufacturing the same are provided. A method for manufacturing a hybrid bonded turbine rotor comprises the steps of providing turbine disk having a rim portion comprising a live rim of circumferentially continuous material and a plurality of live rim notches in an outer periphery of the turbine disk alternating with a plurality of raised blade attachment surfaces defining the outer periphery; providing a plurality of turbine blades, each of which comprising an airfoil portion and a shank portion, the shank portion having a base surface; metallurgically bonding a compliant alloy material layer to either or both of the raised blade attachments surfaces of the turbine disk and the base surfaces of the blade shanks; and linear friction welding the plurality of blades to the turbine disk so as to form a bond plane between the raised blade attachments surfaces of the turbine disk and the base surfaces of the blade shanks, the compliant alloy material layer being disposed at the bond plane.

An additive friction stir deposition device is provided. In one aspect, the device includes a shoulder configured to rotate about a central axis. The shoulder includes a channel extending from a first end of the shoulder to a second end of the shoulder. The channel allows a filler material to pass through the shoulder from the first end towards the second end. The shoulder configured to deposit the filler material as the device is advanced along a deposition surface. The device also includes a wire brush skirt configured to co-rotate with the shoulder and contact the deposition surface as the device is advanced along the deposition surface. The device also includes a gas shroud configured to direct pressurized gas toward the deposition surface and remove contaminants as the device is advanced along the deposition surface.

An additive friction stir deposition device is provided. In one aspect, the device includes a shoulder configured to rotate about a central axis. The shoulder includes a channel extending from a first end of the shoulder to a second end of the shoulder. The channel allows a filler material to pass through the shoulder from the first end towards the second end. The shoulder configured to deposit the filler material as the device is advanced along a deposition surface. The device also includes a wire brush skirt configured to co-rotate with the shoulder and contact the deposition surface as the device is advanced along the deposition surface. The device also includes a gas shroud configured to direct pressurized gas toward the deposition surface and remove contaminants as the device is advanced along the deposition surface.

A method for connecting a nickel ferrite-based ceramic inert anode and a metal conductive block, including: providing a nickel ferrite-based ceramic inert anode and a metal conductive block, and processing surfaces of the nickel ferrite-based ceramic inert anode and the metal conductive block to form surfaces to be connected; providing a transition alloy foil, and attaching the surfaces to be connected of the nickel ferrite-based ceramic inert anode and the metal conductive block respectively to two surfaces of the transition alloy foil to form a prefabricated connection body; performing a vacuum diffusion welding on the prefabricated connection body.

A method for connecting a nickel ferrite-based ceramic inert anode and a metal conductive block, including: providing a nickel ferrite-based ceramic inert anode and a metal conductive block, and processing surfaces of the nickel ferrite-based ceramic inert anode and the metal conductive block to form surfaces to be connected; providing a transition alloy foil, and attaching the surfaces to be connected of the nickel ferrite-based ceramic inert anode and the metal conductive block respectively to two surfaces of the transition alloy foil to form a prefabricated connection body; performing a vacuum diffusion welding on the prefabricated connection body.

The present invention discloses a method of diffusion bonding of nickel alloy and austenitic stainless steel materials. The method involves: heating a bonding interface of the materials by induction heating at a temperature range in an austenitic temperature region under controlled atmospheric pressure; applying a bonding pressure to maintain contact between materials during a bonding process of materials; cooling the bonded materials through specific time frames to ensure proper chemical interactions and minimize defects, and shielding a bonding environment using a controlled ambient atmosphere to reduce impurities, and prevent oxidation and corrosion. The method further involves forming and shaping subcomponents of stainless steel and nickel alloys.